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Subject Replacement of hoses is result of age ...
     
Posted by NytWolf on June 11, 2003 at 5:04 PM
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In Reply To Re: Wish Me Luck!! posted by Biglibby on June 11, 2003 at 04:42 PM
     
Message When pulling the plenum, take your time as it takes alot of patience.

Do your plenum removal in this order. At least, it worked well for me.

1) remove four intake hoses in front (no brainer)
2) remove balance tube (12mm x 5)
3) remove fuel lines and fuel dampers (10mm x 8)
4) unplug injector connectors and coil pack connectors (now is a good time to label your connectors BY NUMBER, if yours aren't labeled)
5) remove coil packs
6) remove hard vacuum pipe on driver's side WITH its hoses attached (I found it easier)
7) with 19mm wrench, remove both vacuum couplings on driver's side of plenum
8) remove the two hard pipes that goes down to the turbos; use a universal joint with 8mm socket to loose the clamps down towards turbo; then pull the hard pipe loose; the clamps shouldn't fall, as they're tied in place
9) remove water bypass hoses:
9a) one on passenger's side that goes straight down towards turbo (most of the coolant in the plenum should come out here)
9b) one on the passenger's side, rear of the plenum (there is a vacuum hose there that comes from the EGR valve, remove this hose too)
9c) one on the middle rear of the plenum; a little bit of coolant should spill
9d) one underneath the driver's side throttle body; the one that goes STRAIGHT down only; some coolant should spill
10) loosen clamps around PCV valves on either side of plenum
11) there are two metal pipes that comes around the underside of the plenum on either side of it; these are held on by four 10mm bolts that come up from the bottom; loosen these bolts with a 10mm wrench, then use a universal joint (or two) with a 10mm socket to remove them
12) pull the wiring harness out of the way, preferably onto the windshield; unplug the connectors to the AIV/IAA (whatever it's called); there should be two toward the back on the driver's side
13) remove the eight bolts holding the plenum down (12mm x 8)
14) grab plenum on both sides and pull up and forward

Took me 20 hours on first try. Now it takes me no more than 2 hours. Good luck!

     
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